粗糙界面法向接触振动响应与能量耗散特性研究

粗糙界面的法向接触振动与能量耗散特性对描述界面动力学机理具有重要的理论和实际意义。本文通过建立粗糙界面法向接触振动的动力学模型,提出了其法向接触振动响应特征量和振动能量耗散量的计算方法。基于粗糙表面的三维分形模型描述,构造了粗糙界面的接触力-变形关系式,并与Hertz接触模型的力-变形关系进行了对比分析;建立了粗糙界面接触振动系统的动力学方程,计算了不同表面形貌粗糙界面系统每周期的振动能量耗散率和累计能量耗散率;分析了粗糙界面法向接触振动的响应特征与能量耗散特性,从理论上对界面法向微动能量耗散的实验结果进行了解释,为描述接触界面的动力学机理提供了理论依据。     

考虑热效应的滚滑并存线接触粗糙界面的摩擦能量耗散特性研究

高速、重载工作条件下,机械结构滚滑并存界面的温度热效应变得显著,可导致系统的动力学特性、磨损特性和工作稳定性等发生根本性变化。通过建立滚滑并存线接触粗糙界面模型,基于界面的法向载荷由润滑油膜和粗糙体共同承担的载荷分配思想,采用Greenwood-Williamson统计模型描述粗糙表面形貌,考虑界面温度热效应的影响,建立了滚滑并存线接触粗糙界面的能量方程、油膜厚度方程和粗糙体接触压力方程,求解了界面温度场,获得了表面粗糙形貌、界面法向载荷和运动速度对热润滑油膜厚度参数和摩擦能量耗散量的影响特性,为机械结构的润滑状态预测和系统动态性能分析提供基础。     

分形粗糙表面加卸载接触特性演变行为分析

粗糙表面加卸载接触特性演变行为对研究界面接触力学性能具有重要的理论意义。基于粗糙表面分形理论,依据修正的双参数Weierstrass-Mandelbrot(W-M)分形函数,采用点云处理技术和Coons patch曲面拟合方法生成三维分形粗糙表面数字模型。根据Prandtl-Reuss本构关系和von Mises屈服准则,选择双线性等向强化非线性材料,建立了精确的分形粗糙表面与刚性平面接触有限元模型。探讨加卸载过程中分形维数和尺度参数对粗糙表面接触载荷、接触面积和变形量的影响;同时,采用核密度估计法分析不同接触状态下粗糙表面形貌高度参数分布的演变规律,并从分形参数和能量角度揭示分形粗糙表面接触特性的内在机理,为进一步研究粗糙表面接触力学性能和载荷传递效率与增强机理提供理论依据。     

基于分形的三维粗糙表面弹塑性接触力学模型与试验验证

基于分形几何理论,利用双变量的Weierstrass-Mandelbrot函数模拟三维分形粗糙表面,建立了三维分形粗糙表面弹塑性接触模型。推导出各等级微凸体发生弹性、弹塑性以及完全塑性变形的存在条件。确定了粗糙表面上各等级微凸体的面积分布密度函数,获得了总接触载荷和真实接触面积之间的关系式。计算结果表明:单个微凸体的临界接触面积与其尺寸相关,随着微凸体等级的增大,微凸体的高度和峰顶曲率半径减小。微凸体的变形顺序为弹性变形、弹塑性变形和完全塑性变形,与经典的赫兹模型保持一致。粗糙表面的力学性能仅与最小等级及后续的6个等级微凸体相关,其余微凸体基本上对整个粗糙表面的力学性能影响很小。最后对粗糙表面的接触力学性能进行了试验测试,验证了该模型的合理性与正确性。     

混合润滑状态下粗糙界面法向接触刚度计算模型与特性研究

机械装备系统的静态特性和动力学特性取决于系统接触界面法向接触刚度。基于粗糙表面形貌的Greenwood-Williamson统计模型描述与液体润滑界面的油膜共振模型和弹簧模型,推导了机械结构混合润滑粗糙界面固体接触刚度和液体润滑介质接触刚度,并实现粗糙微凸体固体接触刚度与液体润滑介质接触刚度的耦合,提出了一种混合润滑状态下粗糙界面法向接触刚度的计算模型,分析了接触界面形貌参数、润滑介质和接触基体材料属性对界面法向接触刚度的影响规律。结果表明:润滑介质的声阻抗是影响液体接触刚度的主要因素,声阻抗增大时,液体接触刚度减小;接触基体材料的表面形貌和弹性模量是影响固体接触刚度的主要因素,界面粗糙度和弹性模量增大时,固体接触刚度增大。混合润滑粗糙界面接触刚度计算模型的提出,为机械结构润滑接触界面的刚度计算、性能预测与优化提供理论和实验参考。     

复合材料螺栓连接松弛的弹-黏塑性分析方法

预紧力松弛是影响复合材料螺栓连接结构耐久性的主要原因之一。本文重点讨论导致预紧力松弛的材料蠕变与粗糙表面接触蠕变的相互影响。内容包括建立了以弹-黏塑性理论为基础的复合材料蠕变本构模型,并结合考虑粗糙表面的分形接触理论,将其推广到与时间相关的弹-黏塑性接触问题。数值结果与实验结果对比表明,考虑粗糙表面接触效应时,计算误差从2.87%~4.37%降至0.04%~0.5%,预测准确性有显著提高。表面分形参数D和G的讨论结果表明,接触表面越粗糙,预紧力越容易松弛。这对工程上通过控制表面形貌参数来改善表面接触性质具有指导意义。     

混合润滑状态下结合面法向动态接触刚度与阻尼模型

机械结合面的动态接触特性对评估机床整机性能有着重要的意义.针对混合润滑状态下固定结合面复杂的接触特性,提出了一种结合面的法向接触刚度与阻尼模型.采用三维Weierstrass?Mandelbrot函数获得粗糙表面形貌,并基于分形理论建立了结合面固体部分的接触刚度与接触阻尼模型;根据平均流动的广义雷诺方程建立了液体油膜接...     

探针尺寸对Si-DLC薄膜表面粘附和摩擦的影响

采用AFM尖头探针、球头探针和平头探针对Si-DLC膜进行摩擦实验,研究了薄膜的微观摩擦力学性能,探讨了不同接触尺度下薄膜表面粘附力及摩擦产生的机理,建立了不同探针与薄膜表面粗糙峰的接触模型,推导了表面粘附力与接触面积的关系表达式,表明在微观接触中,接触面积对粘附力起着主导作用。尖头探针与薄膜表面的微观摩擦系数取决于表面粗糙峰的斜率,与粗糙峰的高度相关不大;球头探针与薄膜表面的摩擦力主要取决于单位面积接触粗糙峰密度;平头探针与薄膜表面的摩擦力主要取决于外加载荷,表面形貌的微观尺寸效应可忽略。     

GIS技术在摩擦学研究中的应用

基于真实表面和地形的相似性,尝试用GIS三维模型的相关技术来解决接触模型中的问题.GIS中的DEM模型是非常成熟的地形描述模型.本文介绍了DEM模型的基本内容以及它和摩擦学接触表面模型的内在相似性,利用DEM的相关技术解决常见的接触模型建模中的色度高度映射表重建问题,利用地表生成技术生成摩擦学粗糙表面.显示了GIS相关技术在摩擦学中应用的可行性.     

硅掺杂类金刚石薄膜微米尺度摩擦性能研究

采用微米级别的AFM球头探针对硅掺杂类金刚石薄膜进行了摩擦实验。研究了微米尺度下,外加载荷和扫描速率对薄膜摩擦性能的影响。考虑粘附的影响,提出了适用于微观低载荷接触摩擦力表征的修正Amonton公式。分析了摩擦系数与表面形貌粗糙峰之间的关系,根据薄膜表面粗糙峰的分布,建立了微米尺度下球头探针与薄膜表面粗糙峰的等效接触模型,并推导出了摩擦力f关于载荷参数(p)和形貌参数()的函数表达式f(p,),表明单位面积接触粗糙峰密度对摩擦力大小起着主导作用。所建接触模型成功解释了摩擦实验现象产生的原因。     

圆弧齿锥齿轮接触动力学分析

运用三角网格方法重构了三维离散的圆弧齿啮合齿面模型。基于多体动力学理论和迟滞接触动力学方法,提出了考虑全齿面动态接触关系的螺旋锥齿轮三维接触动力学模型和动力学分析方法。运用三角网格单元接触的包围盒搜索技术和微分代数方程求解方法,仿真分析了单侧齿面接触、双侧齿面接触、负载扭矩和齿侧侧隙等因素对齿轮啮合传动特性的影响,获得了圆弧齿啮合全齿面接触冲击力,力矩和角速度等齿轮啮合传动的动态响应特性。研究表明：新方法和动力学模型较好地模拟了圆弧齿锥齿轮的承载特性和啮合接触动力学特性,对以动力学特性为目标的圆弧齿锥齿轮设计和齿轮系统动力学研究提供了理论参考。     

Effective mechanical properties of layered rough surfaces

In contact mechanics of layered rough surfaces, found in various systems such as magnetic storage devices and micro/nanoelectromechanical systems, it is of interest to calculate effective elastic modulus and hardness so as to obtain contact parameters using simple analyses for homogeneous surfaces. In this study, effective elastic modulus and hardness of layered rough surfaces are defined on the basis of real area of contact. A numerical model developed by the first author to simulate the contact of layered rough surfaces is used to derive these equations. Completely nondimensionalized empirical equations for these effective mechanical properties are presented. Separate equations are developed for the contact of a single conical asperity on a flat surface, a single spherical asperity on a flat surface, and for multiple asperity contact between two rough surfaces. These equations establish the dependence of effective mechanical properties on indentation depth, layer thickness, hardness and elastic modulus ratios of layer and substrate and surface roughness/asperity geometry. Comparisons of values predicted by the equations with experimentally obtained results are presented. Contact stress contours obtained from this model are analyzed to get a better understanding of the mechanics of contact.     

Performance evaluation of ProJet multi-material jetting 3D printer

The purpose of this paper is to quantitatively evaluate the performance of a multi-material jetting 3D printer, ProJet 5500X, especially the capability for micro manufacturing. Unlike other single material 3D printer, ProJet 5500X uses photopolymers as the build material and wax as the support material. The building performance was evaluated by building a modified version of the standard benchmark model with a high-resolution printing mode. The dimensional error, forming quality and surface roughness of the printed parts have been measured and analysed using a microscope, a 3D coordinate measuring machine and a surface profilometer. Using wax as the support material, fine features as small as 0.25?mm, lateral features and sharper edges could all be properly built, despite the rough side surfaces observed in the printed part. Identical features (3?mm pins) were precisely built with an accuracy of 15?µm. The research provides first-hand detailed performance knowledge in the ProJet system for understanding the working principle and comparison with other 3D printing systems.     

Stabilized numerical solution for transient dynamic contact of inelastic solids on rough surfaces

A simulation technique to deal with transient dynamic contact of tire rubber compounds on rough road surfaces is presented. The segment-to-surface approach is used for modeling the contact between tire tread rubber and road track. While the rubber components are deformable and described by a sophisticated viscoelastic damage constitutive model, the road surface is assumed to be rigid and characterized by an analytical function. A spectral approach based on an inverse computation of the 2D-Fast Fourier transform has been suggested for the reconstruction of rough surface profiles. The Newmark time-stepping method is used for the integration of transient dynamic equations. With the so-called contact-stabilized Newmark method the spurious oscillation at contact boundary has been removed. The detailed investigation on the dynamic contact of inelastic rubber block with rough road surfaces has been made. The robustness of the contact-stabilized Newmark method within a finite deformation framework is underlined by numerical studies, in which it is compared with several dissipation-based stabilization techniques selected from literature.     

Study of speckle size of light scattered from cylindrical rough surfaces

The autocorrelation function of the intensity scattered from cylindrical rough surfaces is analytically obtained with the Kirchhoff scalar diffraction theory. It is shown that, in contrast to the case in which planar rough surfaces scatter radiation, this function, related to the speckle size, depends on the statistical parameters that characterize the surface and on the scattering direction. This result suggests a new, to our knowledge, optical method that can be applied to the characterization of cylindrical rough surfaces, such as in on-line quality assessment, in manufacturing processes. The calculated theoretical expression was tested, showing good agreement with experiments.     

非连续粗糙多界面接触变形和能量损耗特性研究

非连续多层叠加结构的粗糙界面接触形变与能量损耗特性一项研究较少的难题。本文在单一界面能量损耗特性研究的基础上,通过建立“多层粗糙金属板--刚性平面”的多界面模型,采用有限元方法,对加载与卸载过程中,具有不同界面形貌、不同塑性变形行为和界面摩擦的多层叠加模型粗糙多界面的接触力和变形进行计算,研究了多层叠加结构粗糙界面上的接触力-变形关系,以及由塑性变形与界面摩擦引起的能量损耗特性,构造了描述粗糙多界面上接触力-变形关系表达式,计算了多层粗糙界面的能量传递损耗率,分析了多层叠加结构的非连续粗糙多界面接触变形机理和能量损耗特性。     

典型接合面冲击动态响应

舰艇设备中存在着大量的接合面,其在冲击载荷作用下的动力学传递特性是设备响应计算的关键。本文通过试验和数值计算方法对一具有典型接合面的模拟设备在冲击载荷作用下的动响应进行了研究,并对接合面在冲击载荷作用下的动力学特征、冲击载荷沿接合面的传递规律等进行了探讨,研究表明接合面刚度在冲击响应过程中呈非线舰艇设备中存在着大量的接合面,其在冲击载荷作用下的动力学传递特性是设备响应计算的关键。通过试验和数值计算方法对一具有典型接合面的模拟设备在冲击载荷作用下的动响应进行研究,并对接合面在冲击载荷作用下的动力学特征、冲击载荷沿接合面的传递规律等进行探讨,研究表明接合面刚度在冲击响应过程中呈非线性变化,接合面对加速度分布有较大影响,通过试验结果与数值计算结果的对比可知,所采用的接合面数值计算方法具有工程实用精度。性变化,接合面对加速度分布有较大影响,通过试验结果与数值计算结果的对比可知,本文所采用的接合面数值计算方法具有工程实用精度。     

Micro and macro contact mechanics for interacting asperities

Contact of rough surfaces at micro and macro scales is studied in this paper. The asperities at micro scale are characterised by small radius of curvature whereas the waviness is characterised by large radius of curvature. When two rough surfaces come in contact, on the micro scale, of asperities contacts in a very small area leave large gaps between the surfaces; whereas on the macro scale the surfaces conform to each other under the application of load without gaps. Contact at micro scale is modelled by superposition of Hertzian stress fields of individual asperity contacts and the waviness at macro scale is modelled as a mixed boundary problem of rough punch indentation where displacements of uneven profile are prescribed along the region of contact. In both the cases for simplification the roughness is assigned to one surface making the other surface perfectly flat an assumption often made in contact mechanics of rough bodies. The motivation for modelling the asperities at micro scales comes from the preliminary results obtained from photoelastic experiments. Numerical results are presented based on the analytical results available for Hertzian contacts. The motivation for modelling the asperities at macro scales comes from the results available in literature for flat contacts from solving mixed boundary elasticity problems. A condition of full stick is assumed along the contact which is a common assumption made for rough contacts. The numerical results are presented for both the cases of rough contact at micro and macro scales.     

齿面粗糙纹理方向对齿轮润滑效应的影响

 不同的机械加工方法会形成相异的表面粗糙纹理.为了探析不同粗糙纹理对齿轮传动润滑效应之影响,基于实际测量所获得的一系列粗糙度数值,进行了45组数值计算.计算结果显示：当粗糙度均方根值σ≤0.15 μm时,粗糙度对齿面油膜厚度与接触应力影响甚微;当σ>0.15 μm后,随着σ的增大,纵、横向纹理粗糙齿面接触应力均呈线性规律增加,但前者的接触应力始终大于后者.尤其是当σ≥0.55 μm时,与光滑齿面相比,纵、横向纹理粗糙齿面接触应力分别增大90%和80%;与此同时,纵向纹理膜厚值减低40%,而横向纹理膜厚值增大80%以上.在此基础上,针对纵、横向两种粗糙纹理齿面,分别建立了轮齿接触应力与齿面粗糙度之间的回归方程.最后,给出了横向纹理粗糙齿面的润滑效果要优于纵向纹理粗糙齿面的研究结论.     

A consistent approach for fluid-structure-contact interaction based on a porous flow model for rough surface contact

Simulation approaches for fluid-structure-contact interaction, especially if requested to be consistent even down to the real contact scenarios, belong to the most challenging and still unsolved problems in computational mechanics. The main challenges are 2-fold—one is to have a correct physical model for this scenario, and the other is to have a numerical method that is capable of working and being consistent down to a zero gap. Moreover, when analyzing such challenging setups of fluid-structure interaction, which include contact of submersed solid components, it gets obvious that the influence of surface roughness effects is essential for a physical consistent modeling of such configurations. To capture this system behavior, we present a continuum mechanical model that is able to include the effects of the surface microstructure in a fluid-structure-contact interaction framework. An averaged representation for the mixture of fluid and solid on the rough surfaces, which is of major interest for the macroscopic response of such a system, is introduced therein. The inherent coupling of the macroscopic fluid flow and the flow inside the rough surfaces, the stress exchange of all contacting solid bodies involved, and the interaction between fluid and solid are included in the construction of the model. Although the physical model is not restricted to finite element–based methods, a numerical approach with its core based on the cut finite element method, enabling topological changes of the fluid domain to solve the presented model numerically, is introduced. Such a cut finite element method–based approach is able to deal with the numerical challenges mentioned above. Different test cases give a perspective toward the potential capabilities of the presented physical model and numerical approach.